Electronic Cigarette Atomization Assembly and Manufacturing Method Therefor

ABSTRACT

An electronic cigarette atomization assembly includes a porous matrix for conducting cigarette liquid and a heating layer for heating and atomizing the cigarette liquid. The heating layer is disposed on the porous matrix, and connecting portions electrically connected to an electronic cigarette power supply are disposed at two ends of the heating layer, respectively. According to the atomization assembly of the invention, the heating layer and the connecting portions are disposed on the porous matrix, and compared with heating wires in the prior art, the contact area between the heating layer and the porous matrix is larger, so that the atomization area is larger, and the atomization effect is improved. The atomization assembly is simple in structure, the production process is simple, modular, mass and automatic production of the atomization assemblies is realized, the production efficiency is high, and the consistency of the manufactured atomization assemblies is good.

FIELD

The invention relates to the technical field of electronic cigarettes, in particular to an electronic cigarette atomization assembly and a manufacturing method therefor.

BACKGROUND

Atomization assemblies in existing electronic cigarettes are of the following three types:

1) A glass fiber wick or a cotton wick penetrating through the middle of a spiral heating wire to be used as an oil-conducting material for conducting cigarette oil to the surface of the heating wire;

2) A spiral heating wire being wrapped with cotton or non-woven fabric for conducting cigarette oil to the surface of the heating wire;

3) A spiral heating wire being embedded in porous ceramic used as an oil-conducting and heating material.

In these three types of atomization assemblies, the heating wire and the oil-conducting element are assembled by wrapping, so the production process is complex, the cost is high, and the atomization area is small.

SUMMARY

The technical issue to be settled by the invention is to provide an electronic cigarette atomization assembly, which is suitable for modular and automatic production, and a manufacturing method therefor.

The technical solution adopted by the invention to settle the aforesaid technical issue is as follows: providing an electronic cigarette atomization assembly which comprises a porous matrix for conducting cigarette liquid and a heating layer for heating and atomizing the cigarette liquid;

The heating layer is disposed on the porous matrix, and connecting portions configured to be electrically connected to an electronic cigarette power supply are disposed at two ends of the heating layer, respectively.

Preferably, the heating layer is prepared from electronic paste, carbon powder or metal powder that is disposed on a surface of the porous matrix or inside the porous matrix by at least one of printing, coating, spraying, soaking, vacuum plating and sandwiching.

Preferably, the electronic paste comprises at least one of carbon-containing paste, stainless steel-containing paste, silver-containing paste, gold-containing paste, nickel-containing paste, titanium-containing paste, aluminum-containing paste, and copper-containing paste;

The metal powder comprises at least one of stainless steel, nickel, titanium, and nichrome.

Preferably, the porous matrix is made of a porous ceramic material, a carbon material or a foam metal; and the porous ceramic material comprises at least one of mullite, aluminum oxide, silicon dioxide, silicon carbide and diatomite.

Preferably, the heating layer comprises one or multiple heating tapes, and the multiple heating tapes are parallelly distributed at intervals, or connected in a crossed manner; or

The heating layer is mesh-shaped or spiral-shaped.

Preferably, the connecting portions and the heating layer are formed integrally.

Preferably, conductors electrically connected to the electronic cigarette power supply are disposed on the connecting portions.

The invention further provides a manufacturing method for an electronic cigarette atomization assembly, comprising the following steps:

S1: disposing a heating material layer on a whole piece of matrix;

S2: processing the heating material layer into multiple heating layers that arranged at intervals, and forming connecting portions at two ends of each connecting layer, respectively; and

S3: cutting the whole piece of matrix into multiple independent porous matrixes corresponding to the heating layers and the connecting portions at the two ends of the heating layers, each porous matrix with the heating layer and the connecting portions formed thereon forming one atomization assembly.

Preferably, in Step S1, carbon powder or metal powder is disposed on a surface of the whole piece of matrix by vacuum plating or spraying; or, in Step S1, electronic paste is disposed on a surface of the whole piece of matrix by printing, coating, spraying or soaking, and is then baked at a high temperature of 300° C.-1000° C. to be cured to form the heating material layer;

In Step S2, laser cutting or chemical etching is used for processing the heating material layer.

Preferably, in Step S1, a heating material layer is disposed on a surface (surfaces) of one or two green bodies;

Step S2 further comprises: combining the two green bodies to form a whole with the heating material layer sandwiched between the two green bodies; and sintering the matrix green bodies at 300° C.-1000° C. to form a porous matrix;

In the atomization assembly obtained in Step S3, the heating layer is located inside porous matrix, and the connecting portions at the two ends of the heating layer are exposed out of two opposite ends of the porous matrix.

According to the atomization assembly of the invention, the heating layer and the connecting portions are disposed on the porous matrix, and compared with heating wires in the prior art, the contact area between the heating layer and the porous matrix is larger, so that the atomization area is larger, and the atomization effect is improved. The atomization assembly is simple in structure, the production process is simple, modular, mass and automatic production of the atomization assemblies is realized, the production efficiency is high, and the consistency of the manufactured atomization assemblies is good.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be further described below in conjunction with the accompanying drawings and embodiments, characterized in that:

FIG. 1 is a perspective view showing an electronic cigarette atomization assembly according to a first embodiment of the invention;

FIG. 2 is a front view of the electronic cigarette atomization assembly of FIG. 1;

FIG. 3 is a front view showing an electronic cigarette atomization assembly according to a second embodiment of the invention;

FIG. 4 is a front view showing an electronic cigarette atomization assembly according to a third embodiment of the invention;

FIG. 5 is a front view showing an electronic cigarette atomization assembly according to a fourth embodiment of the invention;

FIG. 6 is a front view showing an electronic cigarette atomization assembly according to a fifth embodiment of the invention;

FIG. 7 is a perspective view showing an electronic cigarette atomization assembly according to a sixth of the invention; and

FIG. 8 is a schematic diagram showing a manufacturing process of an electronic cigarette atomization assembly according to an embodiment of the invention.

DESCRIPTION OF THE EMBODIMENTS

To gain a better understanding of the technical features, purposes and effects of the invention, specific implementations of the invention will be described in detail below with reference to the accompanying drawings.

As shown in FIG. 1 and FIG. 2, an atomization assembly 10 for electronic cigarettes according to a first embodiment of the invention comprises a porous matrix 11 and a heating layer 12 disposed on the porous matrix 11.

The porous matrix 11 is used for conducting liquid (cigarette liquid), and is made of a porous ceramic material, a carbon material or a foam metal. The porous ceramic material comprises at least one of mullite, aluminum oxide, silicon dioxide, silicon carbide and diatomite. The porous matrix 11 is a polyhedral structure such as a cubic structure or a cuboid structure, or a cylindrical structure.

The heating layer 12 is a layer structure different from a heating wire, and is used for heating and atomizing the cigarette liquid. Connecting portions 13 configured to be electrically connected to an electronic cigarette power supply are provided at two ends of the heating layer 12, respectively.

The heating layer 12 is disposed on a surface of the porous matrix 11 or inside the porous matrix 11. Corresponding to the shape of the porous matrix 11, the heating layer 12 may be disposed on at least one surface of the porous matrix 11.

The heating layer 12 is prepared from electronic paste, carbon powder or metal powder that is disposed on the surface of the porous matrix 11 or inside the porous matrix 11 by at least one of printing, coating, spraying, soaking, vacuum plating and sandwiching. Wherein the electronic paste comprises at least one of carbon-containing paste, stainless steel-containing paste, silver-containing paste, gold-containing paste, nickel-containing paste, titanium-containing paste, aluminum-containing paste, and copper-containing paste. The metal powder comprises at least one of stainless steel, nickel, titanium, and nichrome.

The size, shape and material of the heating layer 12 are selected according to the resistance required by the heating layer 12.

Optionally, when electronic paste is used to prepare the heating layer 12, the electronic paste is disposed on the porous matrix 11 by printing, coating, spraying or soaking, and is then baked at a high temperature of 300° C.-1000° C. to be cured to form the heating layer 12. When carbon powder or metal powder is used to prepare the heating layer 12, the carbon powder or metal powder is disposed on the porous matrix 11 by vacuum plating or spraying to form the heating layer 12.

The connecting portions 13 and the heating layer 12 are formed integrally. That is, when electronic paste, carbon powder or metal powder is used to prepare the heating layer 12, the connecting portions 13 are formed at the two ends of the heating layer 12 synchronously. In case where the heating layer 12 and the connecting portions 13 are prepared from carbon powder, metal layers may be further disposed on the connecting portions 13 or metal powder may be added to the connecting portions 13 to improve the electrical conductivity of the connecting portions 13.

In this embodiment, as shown in FIG. 1 and FIG. 2, the heating layer 12 is disposed on one surface of the porous matrix 11 and comprises a heating tape 121. The heating tape 121 is linear, and the two connecting portions 13 are connected to two ends of the heating tape 121, respectively. The area of the connecting portions 13 is greater than that of the heating tape 121.

As shown in FIG. 3, an atomization assembly 20 for electronic cigarettes according to a second embodiment of the invention comprises a porous matrix 21 and a heating layer 22 disposed on the porous matrix 21. The porous matrix 21 is used for conducting liquid (cigarette liquid); the heating layer 22 is a layer structure different from a heating wire, and is used for heating and atomizing the cigarette liquid; and connecting portions 23 configured to be electrically connected to an electronic cigarette power supply are disposed at two ends of the heating layer 22, respectively.

The material and arrangement of the porous matrix 21, the heating layer 22 and the connecting portions 23 may be referred to the description of the first embodiment provided above. In this embodiment, the heating layer 22 comprises a heating tape 221, and the two connecting portions 23 are connected to two ends of the heating tape 221, respectively. Different from the first embodiment, the heating tape 221 in this embodiment is wavy or curved. Compared with the linear heating tape 221, the contact area between the wavy or curved heating tape 221 and the porous matrix 21 is larger, such that the atomization area is larger, and the atomization effect is better.

As shown in FIG. 4, an atomization assembly 30 for electronic cigarettes according to a third embodiment of the invention comprises a porous matrix 31 and a heating layer 32 disposed on the porous matrix 31. The porous matrix 31 is used for conducting liquid (cigarette liquid); the heating layer 32 is a layer structure different from a heating wire, and is used for heating and atomizing the cigarette liquid; and connecting portions 33 configured to be electrically connected to an electronic cigarette power supply are disposed at two ends of the heating layer 32, respectively.

The material and arrangement of the porous matrix 31, the heating layer 32 and the connecting portions 33 may be referred to the description of the first embodiment provided above. Different from the first embodiment, the heating layer 32 in this embodiment comprises multiple heating tapes 321, such as two as shown in FIG. 4, or three. The two connecting portions 33 are connected to two ends of the heating tapes 321, respectively.

The multiple heating tapes 321 may be parallelly distributed at intervals, or be connected in a crossed manner.

Compared with one heating tape, the contact area between the multiple heating tapes 321 and the porous matrix 31 is larger, and the heat distribution is more uniform, such that the atomization area is larger, and the atomization effect is better.

As shown in FIG. 5, an atomization assembly 40 for electronic cigarettes according to a fourth embodiment of the invention comprises a porous matrix 41 and a heating layer 42 disposed on the porous matrix 41. The porous matrix 41 is used for conducting liquid (cigarette liquid); the heating layer 42 is a layer structure different from a heating wire, and is used for heating and atomizing the cigarette liquid; and connecting portions 43 configured to be electrically connected to an electronic cigarette power supply are disposed at two ends of the heating layer 42, respectively.

The material and arrangement of the porous matrix 41, the heating layer 42 and the connecting portions 43 may be referred to the description of the first embodiment provided above. Different from the first embodiment, the heating layer 42 in this embodiment is mesh-shaped.

When the heating layer 42 is made, a mesh-shaped tool such as a wire mesh may be disposed on the porous base plate 41 firstly, and then electronic paste, carbon powder or metal powder is disposed on the porous matrix 41 through the wire mesh in a corresponding manner to form the mesh-shaped heating layer 42. Or, electronic paste, carbon powder or metal powder forms the whole heating layer 42 on the porous matrix 41 in a corresponding manner, then a mesh-shaped tool such as a wire mesh is disposed on the porous matrix 41, and finally, the whole heating layer 42 is processed by chemical etching or laser cutting to form a mesh-shaped structure.

In this embodiment, the mesh-shaped heating layer 42 is able to cover a whole surface of the porous matrix 41, so compared with the heating tape, the contact area between the mesh-shaped heating layer 42 and the porous matrix 41 is larger, the heat distribution is more uniform, and thus, the atomization area is larger, and the atomization effect is better.

As shown in FIG. 6, an atomization assembly 50 for electronic cigarettes according to a fifth embodiment of the invention comprises a porous matrix 51 and a heating layer 52 disposed on the porous matrix 51. The porous matrix 51 is used for conducting liquid (cigarette liquid); the heating layer 52 is a layer structure different from a heating wire, and is used for heating and atomizing the cigarette liquid; and connecting portions 53 electrically connected to an electronic cigarette power supply are disposed at two ends of the heating layer 52, respectively.

The material and arrangement of the porous matrix 51, the heating layer 52 and the connecting portions 53 may be referred to the description of the first embodiment provided above. Different from the first embodiment, the porous matrix 51 in this embodiment is cylindrical, and the thickness of the porous matrix 51 may be designed as needed; and the heating layer 52 is disposed on a cylindrical surface of the porous matrix 51 and is spiral. The number of turns of the spiral heating layer 52 may be set according to the size of the surface, where the heating layer 52 is located, of the porous matrix 51, and the heating layer 52 may cover the whole surface or part of the surface.

The spiral heating layer 52 may be prepared with reference to relevant descriptions in the fourth embodiment, and repeated description will be omitted herein.

The atomization assembly 50 in this embodiment is suitable for a cylindrical atomizer.

As shown in FIG. 7, an atomization assembly 60 for electronic cigarettes according to the sixth embodiment of the invention comprises a porous matrix 61 and a heating layer 62 disposed on the porous matrix 61. The porous matrix 61 is used for conducting liquid (cigarette liquid); the heating layer 62 is a layer structure different from a heating wire and is used for heating and atomizing the cigarette liquid; and connecting portions 63 configured to be electrically connected to an electronic cigarette power supply are disposed at two ends of the heating layer 62, respectively.

The material and arrangement of the porous matrix 61, the heating layer 62 and the connecting portions 63 may be referred to the first embodiment. The structure of the heating layer 62 may be referred to the first to fifth embodiments. Different from the first to fifth embodiments, the connecting portions 63 in this embodiment are provided with conductors 64 configured to be electrically connected to the electronic cigarette power supply. Specifically, the two conductors 64 on the two connecting portions 63 are respectively configured to be connected to a positive electrode and a negative electrode of the power supply, so as to form a close circuit.

The conductors 64 may be conducting pillar structures fixed to the connecting portions 63 by spot welding, butt welding, soldering, or laser welding. Connecting sites may be prearranged on the connecting portions 63 to position the conductors 64.

In other embodiments, the heating layer may be sandwiched inside the porous matrix. Specifically, the porous matrix is formed by two matrix units that are combined together, the heating layer is sandwiched between the two matrix units, and the connecting portions are exposed or stretch out of two opposite ends or surfaces of the porous matrix to be electrically connected to the electronic cigarette power supply. Preferably, the heating layer is prepared from electronic paste, and the porous matrix is made of a porous ceramic material.

The invention further provides a manufacturing method for an electronic cigarette atomization assembly, comprising the following steps:

S1: a heating material layer being disposed on a whole piece of matrix;

S2: the heating material layer being processed into multiple heating layers that are arranged at intervals, and connecting portions are formed at two ends of each heating layer, respectively; and

S3: the whole piece of matrix is cut into multiple independent porous matrixes corresponding to the heating layers and the connecting portions at the two ends of the heating layers. Each porous matrix, and the heating layer and connecting portions on the porous matrix cooperatively form one atomization assembly.

The manufacturing method of the invention will be described in detail below with the case where the manufacturing method is used for manufacturing the atomization assembly 10 of the first embodiment as an example.

Referring to FIG. 1 and FIG. 8, in one embodiment, the manufacturing method for the atomization assembly 10 may comprise the following steps:

S1: a heating material layer 110 is disposed on a whole piece of matrix 100, as shown by a side view in FIG. 8(a).

The matrix 100 may be a whole piece of porous ceramic, or a carbon block made of a carbon material.

In one optional implementation, carbon powder or metal powder is disposed on a surface of the whole piece of matrix 100 by vacuum plating or spraying, to form the heating material layer 110 on the surface of the matrix 100.

In another optional implementation, electronic paste is disposed on a surface of the whole piece of matrix 100 by printing, coating, spraying or soaking, and is then baked at a high temperature of 300° C.-1000° C. to be cured to form the heating material layer 110.

S2: the heating material layer 110 is processed into multiple heating layers 12 that are arranged at intervals, and connecting portions 13 are formed at two ends of each heating layer 12, respectively, as shown by a top view in FIG. 8(c).

The heating material layer 110 is processed by laser cutting or chemical etching. Specifically, as shown in by a side view in FIG. 8(b), an organic film 120 is disposed on the heating material layer 110 when the heating material layer 110 is processed. Portions, around the heating layers 12, of the organic film 120 are hollowed out according to the shape of the heating layers 12. Portions, corresponding to the hollowed-out portions of the organic film 120, of the heating material layer are removed by laser cutting or chemical etching. After that, margin waste of the organic film 120 and the heating material layer 110 are removed.

S3: the whole piece of matrix 100 is cut into multiple independent porous matrixes 11 corresponding to the heating layers 12 and the connecting portions 13 at the two ends of the heating layers 12, and each porous matrix 11 with the heating layer 12 and the connecting portions 13 formed thereon form one atomization assembly 10, as shown by FIG. 8(c) to FIG. 8(d).

The matrix 100 may be cut along a cutting line (dotted line) in FIG. 8(c). Laser cutting, wire cutting or abrasive cutting may be used for cutting the matrix 100.

After the matrix 110 is cut, the atomization assembly 10 is cleaned and dried.

It may be understood that the manufacturing method is also suitable for manufacturing the atomization assemblies of the first to sixth embodiments.

According to the manufacturing method for the atomization assembly in other embodiments, conductors electrically connected to an electronic cigarette power supply are disposed on each heating layer before cutting.

According to the manufacturing method for the atomization assembly in other embodiments, the heating layer is arranged in a sandwiched manner, and the manufacturing method may comprise the following steps:

S1: a heating material layer is disposed on a surface (surfaces) of one or two green bodies.

Preferably, the green bodies are porous ceramic green bodies.

S2: the heating material layer is processed into multiple heating layers that are arranged at intervals, and connecting portions are formed at two ends of each heating layer, respectively. The heating material may be processed with reference to the manufacturing method in the above embodiment.

Two green bodies are combined to form a whole with the heating material layer is sandwiched between the two green bodies. The green bodies are sintered at 300° C.-1000° C. to form a porous matrix, such that the structural strength is improved. A hole forming agent in the green bodies is volatized during sintering. The combined green bodies form a whole piece of matrix after being sintered.

S3: the whole piece of matrix is cut into multiple independent porous matrixes corresponding to the heating layers and the connecting portions at the two ends of the heating layers, and each porous matrix with the heating layer and the connecting portions formed thereon form one atomization assembly.

In the atomization assembly, the heating layer is located inside the porous matrix, and the connecting portions at the two ends of the heating layer are exposed out of two opposite ends of the porous matrix to be electrically connected to an electronic cigarette power supply.

To sum up, by adoption of the manufacturing method for the atomization assembly of the invention, multiple atomization assemblies may be manufactured at one time, so that modular, mass and automatic production of atomization assemblies is realized, the consistency is good, and the production efficiency is improved.

The above description is merely used to explain the embodiments of the invention, and is not intended to limit the scope of the patent of invention. All equivalent structural transformations or flow transformations made based on the contents in the specification and drawings of the invention, or direct or indirect applications to other relating technical fields should also fall within the protection scope of the patent of invention. 

1. An electronic cigarette atomization assembly, comprising a porous matrix for conducting cigarette liquid and a heating layer for heating and atomizing the cigarette liquid; wherein the heating layer is disposed on the porous matrix, and connecting portions configured to be electrically connected to an electronic cigarette power supply are provided at two ends of the heating layer, respectively.
 2. The electronic cigarette atomization assembly according to claim 1, wherein the heating layer is prepared from electronic paste, carbon powder or metal powder that is disposed on a surface or inside of the porous matrix by at least one of printing, coating, spraying, soaking, vacuum plating and sandwiching.
 3. The electronic cigarette atomization assembly according to claim 2, wherein the electronic paste comprises at least one of carbon-containing paste, stainless steel-containing paste, silver-containing paste, gold-containing paste, nickel-containing paste, titanium-containing paste, aluminum-containing paste, and copper-containing paste.
 4. The electronic cigarette atomization assembly according to claim 1, wherein the porous matrix is made of a porous ceramic material, a carbon material or a foam metal.
 5. The electronic cigarette atomization assembly according to claim 1, wherein the heating layer comprises one or multiple heating tapes.
 6. The electronic cigarette atomization assembly according to claim 1, wherein the connecting portions and the heating layer are formed integrally.
 7. The electronic cigarette atomization assembly according to claim 1, wherein conductors for being electrically connected to the electronic cigarette power supply are disposed on the connecting portions.
 8. A manufacturing method for the electronic cigarette atomization assembly according to claim 1, wherein the manufacturing method comprises the following steps: S1: disposing a heating material layer on a whole piece of porous matrix; S2: processing the heating material layer into multiple heating layers that are arranged at intervals, and connecting portions being formed at two ends of each connecting layer, respectively; and S3: cutting the whole piece of porous matrix into multiple independent porous matrixes corresponding to the heating layers and the connecting portions at the two ends of the heating layers, each of the porous matrixes with the heating layer and the connecting portions formed thereon forming one said electronic cigarette atomization assembly.
 9. The manufacturing method for the electronic cigarette atomization assembly according to claim 8, wherein in Step S1, carbon powder or metal powder is disposed on a surface of the whole piece of porous matrix by vacuum plating or spraying.
 10. The manufacturing method for the electronic cigarette atomization assembly according to claim 8, wherein in Step S1, a heating material layer is disposed on a surface of one or two green bodies; Step S2 further comprises: combining the two green bodies to form a whole with the heating material layer sandwiched between the two green bodies; and sintering the green bodies at 300° C.-1000° C. to form the porous matrix; and in the atomization assembly obtained in Step S3, the heating layer is located inside the porous matrix, and the connecting portions at the two ends of the heating layer are exposed out of two opposite ends of the porous matrix.
 11. The electronic cigarette atomization assembly according to claim 2, wherein the metal powder comprises at least one of stainless steel, nickel, titanium, and nichrome.
 12. The electronic cigarette atomization assembly according to claim 4, wherein the porous ceramic material comprises at least one of mullite, aluminum oxide, silicon dioxide, silicon carbide and diatomite.
 13. The electronic cigarette atomization assembly according to claim 5, wherein the multiple heating tapes are parallelly distributed at intervals, or connected in a crossed manner.
 14. The electronic cigarette atomization assembly according to claim 1, wherein the heating layer is mesh-shaped or spiral-shaped.
 15. The manufacturing method for the electronic cigarette atomization assembly according to claim 8, wherein the Step 51 comprises: electronic paste being disposed on the surface of the whole piece of porous matrix by printing, coating, spraying or soaking, and then baked at a high temperature of 300° C.-1000° C. to be cured to form the heating material layer.
 16. The manufacturing method for the electronic cigarette atomization assembly according to claim 8, wherein the Step S2 comprises: separating the heating material layer into multiple heating layers by laser cutting or chemical etching. 